Unit of competency Outline

Date retreived
22/07/2026 10:01 PM AWST

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Design a process layout

Design a process layout

Unit of competency
National Code
MSS405022A
State Code
WD559
TGA Status
Replaced
DTWD Status
Replaced
Current Release Number
1.00
Current Release Date
02/05/2012
State Implementation and Classification
Approved Date
29/08/2014
Field of Education
080317 - Quality Management
Original Release Date
29/08/2014
Nominal Hours
80
Description
This unit of competency covers the skills and knowledge required to design a process layout, typically a cellular flow, for either a jobbing shop or a continuous process manufacturer.
Notes
Elements and Performance Criteria
1 Identify the products and processes used in the organisation
  • 1.1 Obtain or develop a process map of the existing process
  • 1.2 Identify all/main products/classes of products
  • 1.3 Obtain forecast sales and sales pattern of products/classes
  • 1.4 Obtain profiles of products/classes
  • 1.5 Group the products/classes into compatible families
2 Engineer the process
  • 2.1 Make a preliminary selection of required equipment/technology/process for each process or product family
  • 2.2 Estimate required resource times for each family
  • 2.3 Calculate total resourcing required for each family
  • 2.4 Estimate appropriate lot size
  • 2.5 Determine viability of proposed families
  • 2.6 Examine draft proposal for possible improvements in process consistent with the competitive systems and practices strategy of the organisation
3 Design the infrastructure
  • 3.1 Consult on layout needs with all stakeholders
  • 3.2 Identify physical infrastructure required by system
  • 3.3 Identify information and control infrastructure required
  • 3.4 Identify work organisation required
  • 3.5 Identify occupational health and safety (OHS) and regulatory requirements to be taken into account
  • 3.6 Identify workforce development and training requirements
  • 3.7 Check the availability of required infrastructure and compatibility with requirements
4 Layout the process
  • 4.1 Draft proposed process flow map
  • 4.2 Draft proposed configuration diagram
  • 4.3 Draft proposed space plan/layout
  • 4.4 Check availability of services/structural suitability, as appropriate
  • 4.5 Validate proposed layout with all relevant stakeholders
  • 4.6 Layout the process/work cell
  • 4.7 Develop implementation plan in liaison with relevant stakeholders
  • 4.8 Review layout after implementation
The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.
Competitive systems and practices

Competitive systems and practices may include, but are not limited to:
lean operations
agile operations
preventative and predictive maintenance approaches
monitoring and data gathering systems, such as Systems Control and Data Acquisition (SCADA) software, Enterprise Resource Planning (ERP) systems, Materials Resource Planning (MRP) and proprietary systems
statistical process control systems, including six sigma and three sigma
Just in Time (JIT), kanban and other pull-related operations control systems
supply, value, and demand chain monitoring and analysis
5S
continuous improvement (kaizen)
breakthrough improvement (kaizen blitz)
cause/effect diagrams
overall equipment effectiveness (OEE)
takt time
process mapping
problem solving
run charts
standard procedures
current reality tree
Competitive systems and practices should be interpreted so as to take into account:
the stage of implementation of competitive systems and practices
the size of the enterprise
the work organisation, culture, regulatory environment and the industry sector
Profiles
Profiles of products may include:
components/materials needed to manufacture
equipment/technology/processes required to manufacture
volume of activity to manufacture forecast amount
Compatible families
Compatible families include:
products/classes requiring identical or similar operations equipment, technology or processes
Required resource times
Required resource times may include:
set-up time
equipment time
person time
process time
Lot size
Lot size may include:
external lot size
internal lot size
transfer batch size
kanban size
Viability
Viability includes:
appropriate calculated processing times
adequacy of equipment utilisation
acceptable maintenance implications
ability to meet OHS requirements
ability to meet environmental requirements
compliance with any legislative and regulatory requirements
acceptable to stakeholders
Stakeholders
Stakeholders include:
customers
employees
equipment suppliers and contractors (especially if new equipment required)
Depending on the process and location, stakeholders may also include:
regulatory authorities
local community representatives
utilities (e.g. water and power)
Physical infrastructure
Physical infrastructure may include:
containers
material handling equipment
utilities supply (e.g. steam, air, gas, electricity and water)
Information and control infrastructure
Information and control infrastructure may include:
quality assurance
statistical process control (SPC)/six sigma
planning systems/software
data collection and control systems/software
Work organisation

Work organisation includes:
number of personnel
skills mix of workforce
The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.
Critical aspects for assessment and evidence required to demonstrate competency in this unit
A person who demonstrates competency in this unit must be able to provide evidence of their ability to:
analyse products, operations and equipment and determine efficiencies that can be achieved by improved layout
determine OHS and regulatory impacts on a layout
supervise implementation of layouts
analyse implemented layouts and suggest further improvements.
Context of and specific resources for assessment
Assessment of performance must be undertaken in a workplace using or implementing one or more competitive systems and practices.
Access may be required to:
workplace procedures and plans relevant to work area
specifications and documentation relating to planned, currently being implemented, or implemented changes to work processes and procedures relevant to the assessee
documentation and information in relation to production, waste, overheads and hazard control/management
reports from supervisors/managers
case studies and scenarios to assess responses to contingencies.
Method of assessment
A holistic approach should be taken to the assessment.
Competence in this unit may be assessed by using a combination of the following to generate evidence:
demonstration in the workplace
workplace projects
suitable simulation
case studies/scenarios (particularly for assessment of contingencies, improvement scenarios, and so on)
targeted questioning
reports from supervisors, peers and colleagues (third-party reports)
portfolio of evidence
In all cases it is expected that practical assessment will be combined with targeted questioning to assess underpinning knowledge.
Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.
Guidance information for assessment
Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the candidate and the work being performed.
Replaced By
State Code National Code Title Type
BAJ92 MSS405022 Design a process layout Unit of competency